Why is leak testing important? Leak testing: everything you need to know

Want to ensure the integrity of your packaging or product? Then leak testing should be high on your agenda. It’s one of the most widely used testing methods – and there’s good reason for that. It’s non-destructive, fast and offers important assurances for users.  

Why is leak testing important?

Whatever you manufacture, you must prove the products you make and the packaging you use for them don’t contain imperfections or problem areas that could cause an ‘unacceptable’ flow of liquid or gas from an item. Or even let unwanted atmospheric and environmental contaminants enter the space. Leaks can cause massive problems for all kinds of products and packaging – making it an essential part of any QA process.  

What is leak testing?

Leak testing is a non-destructive testing method that allows you to determine whether there is a point of ingress in a sealed environment. It typically uses pressure to pinpoint any defects. There are many different leak testing methods, including pressure decay testing, mass flow testing and occlusion testing.  

For more handy information, or some insight into the lingo, check out our leak testing glossary. You’ll also find out more in our complete guide to leak testing, which answers lots of commonly asked questions about the process.   

What industries use leak testing?

Companies across all industries – from aerospace to electronics, and from food through to pharmaceuticals – must prove their goods are fit for purpose. So, choosing and investing in the right leak testing methods is important. Whether you make flexible packages, sterile medical bags or car parts… your products must comply with all relevant quality and environmental standards.  

Testing for ‘unacceptable’ leaks 

It’s true that everything leaks over time. But depending on the specifics of the product or packaging there’s differences in what constitutes ‘unacceptable.’ You might have one small hole to contend with. Or find that your goods and the packaging you purchased are riddled with them! First you must decide upon how much leakage you’ll allow either into, or out of, your product or package. 

Once you have determined the acceptable ‘leak rate,’ a solid leak testing inspection process will keep you on the right side of the regulator. Leak test variables such as the size of the hole(s), the gas type your products are exposed to and the pressure differential between the inside, and the outside, of your packages or products, are considered. 

Sector specific leak testing

There’s a different type of leak test for every industry and each caters to the specific situations you may find yourself in. Here’ are just a few cross-sector considerations: 

● Automotive: leak testers are vital for many components of any vehicle to meet stringent environmental, safety and function guidelines 

● Healthcare: leak tests guarantee a sterile environment in the packaging of a medical device for a healthcare setting. Or confirm that a batch of life-saving IV tubing sets are free from occlusion. For more insight, read our guide to leak testing medical equipment 

● Food: to extend the product’s lifetime and maintain a carefully blended headspace gas mix; effective leak testing can ensure use and sell by dates 

● Heavy industry: think about human health and safety focused leak tests – your products may contain toxic chemicals, or even change to a hazardous state when exposed to the elements 

● Pharmaceuticals: leak testing machines can guarantee efficacy of a drug when exposure to air or environmental contaminants could damage its potency 

● Consumer electronics: leak testing will ensure that your product can hold up to the environment its users are subject to. Check out our guide to leak testing electronics. 

● Flexible packaging: package leak testing for leak-tight assurance is vital for manufacturers in every sector. 

Find the right leak testing solution

Across the Industrial Physics family of brands we design, make and sell the best leak testing equipment on the market. Whether you need a catheter leak tester or help with pressure decay leak testing, we can plug any gaps in your knowledge or inspection processes. Browse our full range of leak testing solutions.